Global rice consumption for 2023/24 is anticipated to reach an unprecedented 523.9 million tons.* The global rice market size was valued at USD 287.45 billion in 2021** We’ll look at several applications of Lean and Six Sigma to rice production in Thailand, Australia, and Indonesia and finish with a video of how rice is processed.




Six Sigma Used to Reduce Rice Packaging Defects: Thailand

In a paper titled “Defect Reduction in Ready Rice Packaging by Applying Six Sigma,” authors Angsumalin Senjuntichai, Nuttapong Wonganawat, and Boonwa Thampitakkul discuss the use of Six Sigma to reduce the defects in rice packaging.

The paper includes:

  • Photos of Defects: Unreadable, Wrinkle of Seal, Out of Shape
  • Pareto Chart of Waste Defects
  • FMEA RPN Numbers by Causes
  • Selected Special Causes
  • Design of Experiments (DOE) Factor Settings

You can read the paper here:


Rice Milling and Six Sigma: Australia

In a short paper titled “Development of Rice Milling In-Line Process Control,” Project Engineer Owen Hennicke discusses the use of Six Sigma as a continuous improvement methodology for rice milling.

Six Sigma Pilot Projects Selected at SunRice were:

  • Milling Yield (Leeton Mill huller losses)
  • Paddy Drying (drying accuracy & losses)
  • Packaging Improvements (film friction & performance)
  • Supply Chain Claims (business process re-design)
  • Procurement Review (business process review)

The paper's discussion of the Six Sigma pilot projects was confined to the Milling Yield Project.

The project achieved significant reductions in whole grain rice losses due to

inefficiencies in the hulling process.

You can access the paper here:


Using Six Sigma to Reduce Rice Milling Defects: Indonesia

In a case study titled “Product Defects Analysis Using Six Sigma Method—A Case Study at Rice Milling Company,” authors Indah Chyntia Bella Rosa and others discuss using Six Sigma to reduce rice milling defects.

The case study includes:

  • Total Production By Week
  • Pareto Chart of Rice Production Defects
  • Cause and Effect Diagram for Rice Product Defects

You can read the case study here:


Lean Production Management for Rice Supply Chain Efficiency: Indonesia

In a case study titled “Lean management in the rice industry; case study at Widasari, Indramayu district,” authors T. Perdana and others discuss the use of value stream mapping to develop a model of

efficiency with the concept of Lean production management.

The case study includes:

  • Current Rice Supply Chain Map
  • SIPOC for Rice Production Process
  • Rice Industry Schematic
  • PERT Analysis in the Rice Value Stream Process
  • Current State Value Stream Map
  • Future Value Stream Map

You can read the case study here:

[Citation: T Perdana et al 2019 IOP Conf. Ser.: Earth Environ. Sci. 335 012024]


How is Rice Processed?

See how rice is processed in this video from How It’s Made.

You can watch the video here:

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